Flow control for multiple stacks

ABSTRACT

A fuel cell comprises an electrode plate having a flow field formed therein and a proton exchange membrane. A compressible permeable diffusion media is disposed adjacent the electrode plate. The diffusion media is compressed against the electrode plate so that a portion of the media intrudes into the flow field. A fuel cell stack can be made by compressing a plurality these fuel cells together. The fuel cell stack is compressed so that the diffusion media in each fuel cell is compressed against the adjacent electrode plate with a portion of the media intruding into the flow field in the adjacent electrode plate. The compression of the fuel cell stack can be adjusted so that a magnitude of intrusion of the diffusion media into the flow channels is adjusted and a pressure drop of a predetermined magnitude occurs across the fuel cell stack at a desired operational state.

FIELD OF THE INVENTION

The present invention relates to fuel cells and more particularly tocontrolling the flow of reactants through a fuel cell.

BACKGROUND OF THE INVENTION

Fuel cells have been used as a power source in many applications. Forexample, fuel cells have been proposed for use in electrical vehicularpower plants to replace internal combustion engines. In proton exchangemembrane (PEM) type fuel cells, hydrogen is supplied to the anode of thefuel cell and oxygen is supplied as the oxidant to the cathode. PEM fuelcells include a membrane electrode assembly (MEA) comprising a thin,proton transmissive non-electrically conductive, solid polymerelectrolyte membrane having the anode catalyst on one face and thecathode catalyst on the opposite face. The MEA is sandwiched between apair of non-porous, electrically conductive elements or plates which (1)serve as current collectors for the anode and cathode, and (2) containappropriate channels and/or openings formed therein for distributing thefuel cell's gaseous reactants over the surfaces of the respective anodeand cathode catalysts.

The term “fuel cell” is typically used to refer to either a single cellor a plurality of cells (stack) depending on the context. A plurality ofindividual cells are typically bundled together to form a fuel cellstack and are commonly arranged in electrical series. Each cell withinthe stack includes the membrane electrode assembly (MEA) describedearlier, and each such MEA provides its increment of voltage. A group ofadjacent cells within the stack is referred to as a cluster.

In PEM fuel cells, hydrogen (H₂) is the anode reactant (i.e., fuel) andoxygen is the cathode reactant (i.e., oxidant). The oxygen can be eithera pure form (O₂) or air (a mixture of O₂ and N₂). The solid polymerelectrolytes are typically made from ion exchange resins such aperfluoronated sulfonic acid. The anode/cathode typically comprisesfinely divided catalytic particles, which are often supported on carbonparticles, and mixed with a proton conductive resin. The catalyticparticles are typically costly precious metal particles. As such, theseMEAs are relatively expensive to manufacture and require certainconditions, including proper water management and humidification andcontrol of catalyst fouling constituents such as carbon monoxide (CO),for effective operation.

The electrically conductive plates sandwiching the MEAs may contain anarray of grooves in the faces thereof that define a reactant flow fieldfor distributing the fuel cell's gaseous reactants (i.e., hydrogen andoxygen in the form of air) over the surfaces of the respective cathodeand anode. These reactant flow fields generally include a plurality oflands that define a plurality of flow channels therebetween throughwhich the gaseous reactants flow from a supply header at one end of theflow channels to an exhaust header at the opposite end of the flowchannels.

Interposed between the reactant flow fields and the MEA is a diffusionmedia serving several functions. One of these functions is the diffusionof reactant gases therethrough for reacting with the respective catalystlayer. Another is to diffuse reaction products, such as water, acrossthe fuel cell. In order to properly perform these functions, thediffusion media must be sufficiently porous while maintaining sufficientstrength. Strength is required to prevent the diffusion media fromtearing when assembled within the fuel cell stack.

The flow fields are carefully sized so that at a certain flow rate of areactant, a specified pressure drop between the flow field inlet and theflow field outlet is obtained. At higher flow rates, a higher pressuredrop is obtained while at lower flow rates, a lower pressure drop isobtained. However, the pressure drop experienced between the flow fieldinlet and the flow field outlet may vary from the designed pressuredrop. Such variations can be caused by variations in the manufacturingof the fuel cell stacks and/or in the tolerances of the components usedin the fuel cell stack. Such variations from the designed pressure dropcan be detrimental to the operation and/or performance. Therefore, it isdesirable to provide a fuel cell and/or fuel cell stack having animproved flow field design.

SUMMARY OF THE INVENTION

The present invention provides a fuel cell that has a pressure drop thatcan be varied. A compressible diffusion media for implementation with afuel cell is utilized. The compressible nature of the diffusion mediaenables the pressure drop across the fuel cell to be adjusted so that adesired operation of the fuel cell can be achieved.

A fuel cell according to the present invention has an electrode platewith a flow field formed therein and a proton exchange membrane. Acompressible, fluid-permeable diffusion media is disposed adjacent tothe electrode plate. The media is compressed against the electrode plateso that a portion of the media intrudes into the flow field.

The present invention discloses a method of making an individual fuelcell. The method includes the steps of: (a) positioning a compressible,fluid-permeable diffusion media in between a proton exchange membraneand an electrode plate having a flow field formed therein; and (b)compressing the diffusion media against the electrode plate so that aportion of the media intrudes into the flow field.

The present invention also discloses a method of making a fuel cellstack. The method includes the steps of: (a) positioning a plurality offuel cells adjacent one another; (b) supplying a feed stream to theplurality of fuel cells; (c) monitoring a pressure drop of the feedstream across the plurality of fuel cells; and (d) adjusting acompression of the plurality of fuel cells so that the pressure drop isof a magnitude substantially equal to at least one of a predeterminedrange of pressure drops and a predetermined pressure drop.

By the present invention it is possible to compensate for possiblevariations in the designed pressure drop, it is also possible to controlthe amount of pressure drop that is experienced so that a relativelycustomized operation of the fuel cell can be achieved. For example, onepressure drop may be implemented to enhance performance of the fuel cellwhile a different pressure drop may be implemented to enhance anefficiency of the fuel cell system. Additionally, when a fuel cell stackis connected in parallel with one or more other fuel cell stacks suchthat they all receive a feed stream from a common header, it is possibleto adjust the pressure drops of one or more of the various fuel cellstacks so that the feed stream from the header flows evenly through eachof the fuel cell stacks. That is, if one fuel cell stack has a lowerpressure drop than other fuel cell stacks that are operated in parallel,a greater portion of the feed stream will flow through the lowerpressure drop stack than through the higher pressure drop stacks. Suchvariation in the portions of the feed stream that flow through thevarious fuel cell stacks may be controlled or mitigated byimplementation of the invention.

Thus, it is possible to control and/or adjust the amount of pressuredrop that occurs across the flow fields in the fuel cell and/or fuelcell stack so that specific operational performance can be achieved.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is an exploded perspective view of a monocell fuel cell accordingto the principles of the present invention;

FIG. 2 is a partial perspective cross-sectional view of a portion of aPEM fuel cell stack containing a plurality of the fuel cells of FIG. 1,showing layering including diffusion media;

FIG. 3 is a detailed view of the portion shown in FIG. 2;

FIG. 4 is a simplified cross-sectional view of a fuel cell stack beingcompressed according to the principles of the present invention; and

FIG. 5 is a schematic representation of a plurality of fuel cell stacksoperating in parallel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following description of the preferred embodiment is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

With reference to FIG. 1, a monocell fuel cell 10 is shown having an MEA12 and a pair of diffusion media 32 sandwiched between a pair ofelectrically conductive electrode plates 14. It will be appreciated,however, that the present invention, as described hereinbelow, isequally applicable to fuel cell stacks 15 that comprise a plurality ofsingle cells arranged in series and separated from one another bybipolar electrode plates commonly known in the art. Such fuel cellstacks 15 are shown in FIGS. 4 and 5. For brevity, further reference maybe made to either the fuel cell stack 15 or to an individual fuel cell10, however, it should be understood that the discussions anddescriptions associated with fuel cell stack 15 are also applicable toindividual fuel cells 10 and vice versa and are within the scope of thepresent invention.

The plates 14 may be formed of carbon, graphite, coated plates orcorrosion resistant metals. The MEA 12 and electrode plates 14 areclamped together between end plates 16. The electrode plates 14 eachcontain a plurality of lands 18 defining a plurality of flow channels 20that form a flow field 22 for distributing reactant gases (i.e. H₂ andO₂) to opposing faces of the MEA 12. In the case of a multi-cell fuelcell stack 15, a flow field is formed on either side of the bipolarplate, one for H₂ and one for O₂. Nonconductive gaskets 24 provide sealsand electrical insulation between the several components of the fuelcell 10. Insulated bolts (not shown) extend through holes located at thecorners of the several components for clamping the fuel cell 10together.

With particular reference to FIGS. 2 and 3, the MEA 12 includes amembrane 26 sandwiched between an anode catalyst layer 28 and a cathodecatalyst layer 30. An anode diffusion media 32 a and a cathode diffusionmedia 32 c are interposed between the MEA 12 and the plate 14. As shown,H₂ flow channels 20, forming the anode side H₂ flow field, lieimmediately adjacent the anode diffusion media 32 a and are in directfluid communication therewith. Similarly, O₂ flow channels 20, formingthe cathode side O₂ flow field, lie immediately adjacent the cathodediffusion media 32 c and are in direct fluid communication therewith.The membrane 26 is preferably a proton exchange membrane (PEM) and thecell having the PEM is referred to as a PEM fuel cell.

In operation, the H₂-containing reformate stream or pure H₂ stream (fuelfeed stream) flows into an inlet side of the anode side flow field andconcurrently, the O₂-containing reformate stream (air) or pure O₂ stream(oxidant feed stream) flows into an inlet side of the cathode side flowfield. H₂ flows through anode diffusion media 32 a and the presence ofthe anode catalyst 28 causes the H₂ to break into hydrogen ions (H⁺),with each giving up an electron. The electrons travel from the anodeside to an electric circuit (not shown) for enabling work to beperformed (i.e. rotation of an electric motor). The membrane layer 26enables the H⁺-ion to flow through while preventing electron flowtherethrough. Thus, the H⁺-ions flow directly through the membrane tothe cathode catalyst 28. On the cathode side, the H⁺-ions combine withO₂ and the electrons returning from the electric circuit, therebyforming water.

Still referring to FIGS. 2 and 3, flow channels 20 and MEA 12 are shown.Flow channels 20 are sized to have a specific flow area 34 through whichthe feed streams flow. The flow area 34 is sized so that at a certainflow rate of the feed streams through the flow channels 20, a specificpressure drop occurs across the flow field 22. That is, at a certainflow rate the gaseous reactants flowing through the channels 20 willexperience a pressure drop between an inlet and an outlet of the flowfield 22. The flow rate of the feed streams through the flow field 22may vary depending upon the operation of the fuel cell stack 15, such aswhen higher or lower power output is required. At times, it may bedesirable to alter the specific pressure drop that occurs across flowfield 22 for a specific flow rate of a feed stream.

To change the pressure drop that occurs across flow field 22 for aspecific flow rate of a feed stream, diffusion media 32, as shown inFIGS. 2 and 3, is compressible and can be compressed into flow channels20 of flow field 22. Specifically, MEA 12 is compressed between adjacentelectrode plates 14 so that a portion 36 of compressible media 32intrudes into flow channels 20. As shown in FIGS. 4A and 4B, fuel cellstack 15 is compressed by an adjustable compressing member 38 thatapplies a compressive force F which causes the plurality of fuel cells10 to compress together and causes compressible diffusion media 32 tocompress and intrude into flow channels 20 of flow field 22. Preferably,compressible media 32 elastically deforms between about 0-50%. Morespecifically, a cross-sectional area of compressible media 32 preferablyelastically deforms between about 0-50%. The intrusion of portions 36 ofdiffusion media 32 into flow channels 20 reduces flow area 34. Reductionin flow area 34 restricts flow of a feed stream through flow channel 20and flow field 22. The restriction causes an increased pressure drop tooccur for a given flow rate of the feed stream. The amount of intrusionof media 32 into flow channels 20 is dependent upon a variety offactors, such as the specific characteristics of diffusion media 32, thegeometry/dimensions (depth and width) of flow channels 20 and the amountof force F applied. The variable restriction of the flow channels 20allows for control of a feed stream flowing through flow channel 20.

Diffusion media 32, as was stated above, is used as both an anodediffusion media 32 a and a cathode diffusion media 32 c. Diffusion media32 can be compressible or non-compressible at the typical forces F thatare applied to fuel stack 15. Typically, fuel cell stack 15 iscompressed an amount that causes a pressure in a range between about25-200 psi to be experienced across a total cross-sectional area of fuelcell stack 15. Because of gaps, voids and spaces in the variouscomponents that comprise the fuel cells 10 and the fuel cell stack 15,only about 50% of the total cross-sectional area is typically in contactwith other components. Therefore, a typical fuel cell stack 15 iscompressed an amount that causes a compressive force or pressure in arange between about 50-400 psi to be experienced by fuel cell stack 15.It should be understood, however, that other compressive forces can beapplied and still be within the scope of the present invention. Itshould also be understood that the terms “compressible” and“non-compressible” as used herein are relative terms that are used todescribe the ability of one diffusion media 32 to be compressed andintrude into flow channels 20 at the range of compressive forcesexpected to be encountered in a fuel cell stack 15, relative to anotherdiffusion media 32 not intruding into flow channels 20 any significantamount at the same range of compressive forces expected to beencountered. A significant amount of intrusion into flow channel 20 isthat which allows a flow in the flow channel to be adjusted andcontrolled as described herein. In other words, non-compressibleindicates the media has essentially no discernable or functional effecton the flow through the channel.

As was stated above, diffusion media 32 can be provided in either acompressible form or a non-compressible form, depending upon theapplication and design specifications for the fuel cell 10. Preferably,only one of the diffusion media 32 a or 32 c is compressible while theother is non-compressible. By having only one type (anode or cathode) ofdiffusion media 32 compressible, one set of flow channels 20 can besized for a specific pressure drop at a given flow rate while the otherset of channels 20 have a flow area 34 that will vary with thecompression of the fuel cells 10. This in turn allows for the operationof the fuel cell stack 15 to be adjusted to a desired operation, as willbe discussed below. It should be appreciated, however, that bothdiffusion media 32 a and 32 c can be compressible and still be withinthe scope of the present invention. It should also be understood thatnot all of the fuel cells 10 that comprise fuel cell stack 15 need tohave a compressible media 32 to be within the scope of the invention.That is, the number of fuel cells 10 that have a compressible media 32that comprise fuel cell stack 15 can vary depending upon the design ofthe fuel cell stack 15. Therefore, fuel cell stack 15 can include somefuel cells 10 that do not have a compressible media 32 and still bewithin the scope of the present invention.

The choice of whether to have a compressible anode diffusion media 32 aor a compressible cathode diffusion media 32 c will depend upon adesired operation and control of fuel cell stack 15. For example, whenthe fuel supplied to the fuel cell 10 is an H₂-containing reformatestream from a reforming system, it is preferred to adjust flow area 34in anode flow channels 20 by providing a compressible anode diffusionmedia 32 a. The use of a compressible anode diffusion media 32 a enablesthe amount of reformate fuel flowing through the anode flow channels 20to be accurately controlled. This is preferred because reformate fuel istypically provided by an onboard reforming system that uses energyproduced by the fuel cell system to generate the reformate fuel. Sinceenergy is being expended to produce the reformate fuel, it is preferredto supply only the needed (required) amount of reformate fuel tominimize any waste. The reduction in the amount of reformate fuel in theanode exhaust (waste) allows for more efficient operation of the fuelcell system within which the fuel cells 10 operate. Therefore, when areformate fuel is used, it is preferred that anode diffusion media 32 abe compressible while cathode diffusion media 32 c be non-compressible.

In contrast, when the fuel feed stream is H₂ from an onboard H₂ storagetank, it is preferred to adjust flow area 34 in cathode flow channels 20by providing a compressible cathode diffusion media 32 c. This ispreferred because little or no energy is consumed by the fuel cellsystem to provide the H₂ fuel feed stream from the storage tank whileenergy from the fuel cell system is used to provide the oxidant feedstream in the form of compressor work. By controlling the pressure dropthrough the cathode flow channels 20 via compressible cathode diffusionmedia 32 c, the use of the compressed oxidant feed stream can beminimized and/or optimized so that energy loss associated with excesscompressor work is minimized. Additionally, by controlling the flowthrough the cathode flow channels 20, it is easier to keep fuel cellstack 15 humidified.

With respect to the performance requirements of diffusion media 32,along with being compressible or non-compressible, diffusion media 32should be sufficiently electrically conductive, thermally conductive andfluid permeable. The fluid permeability of diffusion media 32 must behigh for transporting reactant gas and/or H₂O under lands 18 disposedbetween flow channels 20, the electrical conductivity must be high totransport electrons over flow channels 20 from lands 18 to MEA 12 andthe thermal conductivity must be sufficient to transfer heat to theplate which is then dissipated through coolant in contact with theplate.

Diffusion media 32 enables the diffusion of the reactants (i.e., H₂ andO₂ ), as well as the reaction products (i.e., H₂O) therethrough. In thismanner, the reactants are able to flow from flow channels 20, throughdiffusion media 32 and into contact with their respective catalysts forenabling the required reaction. As described previously, one product ofthe reaction is H₂O. The redistribution of H₂O across fuel cell 10 is ofsignificant importance to the performance of fuel cell 10. Diffusionmedia 32 enables the flow of H₂O therethrough, from more hydrated areasto drier areas for homogeneously hydrating fuel cell 10. Further, theflow of electrons is also a significant factor in the performance offuel cell 10. Inhibited electron flow results in poor performance andinefficiency.

Non-compressible diffusion media having the above statedcharacteristics, such as 060 TORAY® carbon paper, are known in the artand will not be described further. A compressible media 32 having thesecharacteristics can be made from a variety of materials. For example, awoven carbon paper, such as V3 elat single side diffuser available fromE-TEK division of De Nora N. A. of Sommerset, N.J., and CF clothavailable from SGL Carbon AG of Wiesbaden, Germany, can be used as acompressible diffusion media. Furthermore, other materials havingsimilar properties to the above mentioned materials can also beemployed.

Fuel cell stack 15 can be compressed to provide a specific pressure dropfor a desired operating state. The specific pressure drop experienced bya feed stream will vary depending upon a flow rate of the feed steamthrough flow channels 20. The variation in the pressure drop with theflow rate is approximately linear for the pressure drops and flow ratesutilized in a typical fuel cell stack 15. Typical pressure drops are inthe range of about 0.1-6.0 psi across the plate. However, other pressuredrops can be employed without departing from the scope of the presentinvention.

The specific pressure drop across fuel cell stack 15 can be adjusted tocoincide with a desired operating state of the fuel cell stack 15. Whenpeak power is the most important or critical aspect of operation of fuelcell stack 15, compression of fuel cell stack 15 can be adjusted so thata desired pressure drop across flow fields 22 occur at a specific poweroutput of fuel cell stack 15. To ensure peak power performance, thepressure drop is set while fuel cell stack 15 is operating at a highpower level (i.e., 85-100% of peak power), as will be described in moredetail below. When efficiency of fuel cell stack 15 is the mostimportant or critical aspect of operation of fuel cell stack 15,compression of fuel cell stack 15 can be adjusted so that a desiredpressure drop across flow fields 22 occur at a specific power output offuel cell stack 15. To ensure peak efficiency, the pressure drop is setwhile fuel cell stack 15 is operating at a lower power level (i.e.,10-30% of peak power), as will be described in more detail below.

The pressure drop that occurs across flow field 22 can be set so that aminimum velocity of a feed stream flowing through flow fields 22 ismaintained. Maintaining a minimum velocity is desirable (especially atlow power operation) to ensure that an adequate shear force or dynamicpressure is generated by the feed stream to transport reaction products(H₂O) out of the fuel cells 10 to allow the gaseous reactants clearaccess to catalyst layers 28 and 30. The pressure drop can be adjustedso that at a minimum expected flow rate of a feed stream to fuel cellstack 15, a sufficient velocity is maintained through flow channels 20such that an adequate shear force or dynamic pressure is generated andmaintained.

Compressible diffusion media 32 can be compressed to varying degrees asdictated by the application within which the compressible diffusionmedia 32 is utilized. It is envisioned that the typical compression willbe in the range of about 10 to 50%. However, it should be understoodthat other amounts of compression can be employed without departing fromthe scope of the present invention. The actual amount of compressionwill vary depending upon, among other things, the channel geometry(width and depth of the channels), the desired operation of fuel cellstack 15 (desired pressure drop and/or desired flow velocity), and thespecific diffusion media used. Electrode plates 14 may employ anelectrically conductive coating that requires compression to effectivelyconduct electricity. That is, the coatings on electrode plates 14exhibit contact resistance and are not sufficiently conductive withoutbeing compressed. The envisioned 10% minimum compression accounts forvariations in the manufacturing and tolerances of the components thatcomprise fuel cell stack 15 and ensures adequate compression and contactbetween compressible diffusion media 32 and adjacent electrode plates 14so that the contact resistance of the electrode plates 14 is less than anominal value. The compression requirements of such coatings can varydepending upon the exact nature of the coating and the design of theplates 14.

The use of a compressible diffusion media 32 that allows for adjustmentto a pressure drop of a feed stream flowing through fuel cell stack 15enables the pressure drop of a fuel cell stack 15 to be adjusted tomatch a pressure drop of a different fuel cell stack and/or for a fuelcell stack 15 to be built to a specific pressure drop or range ofpressure drop. For example, referring now to FIG. 5, a plurality of fuelcell stacks are shown operating in parallel. A first fuel cell stack 38is shown operating in parallel with a second fuel cell stack 40 whichboth operate in parallel with an n^(th) fuel cell stack 42. The fuelcell stacks 38, 40 and 42 operate in parallel such that the fuel cellstacks 38, 40 and 42 all share a feed stream 44 from a common feedstream header 46. Each fuel cell stack 38, 40 and 42 receives respectiveportions 48, 50 and 52 of feed stream 44. The pressure drops across eachof the fuel cell stacks 38, 40 and 42 dictate the flow distribution ofthe feed stream 44 into portions 48, 50 and 52. That is, the size ofportions 48, 50 and 52 received by fuel cell stacks 38, 40 and 42,respectively, are determined by the pressure drops of the individualfuel cell stacks 38, 40 and 42. If the fuel cell stacks 38, 40 and 42have different pressure drops, then each fuel cell stack 38, 40 and 42will receive a different size portion 48, 50 and 52 of feed stream 44.The non-uniform flow distribution to fuel cell stacks 38, 40 and 42 maybe undesirable.

To compensate for the variations in the pressure drops of the parallelfuel cell stacks 38, 40 and 42, fuel cell systems have taken variousapproaches. A first approach has been incorporating independent flowmetering components that monitor and control the portions 48, 50 and 52received by the fuel cell stacks 38, 40 and 42 so that each fuel cellstack 38, 40 and 42 each receive an adequate portion 48, 50 and 52 offeed stream 44. A second approach has been to supply fuel cell stacks38, 40 and 42 with an excessive flow of feed stream 44 so that each fuelcell stack 38, 40 and 42 receives an adequate portion 48, 50 and 52 offeed stream 44. The present invention can compensate for the variationsin the pressure drops of the fuel cell stacks 38, 40 and 42 without thenecessity of having independent flow metering components or supplying anexcessive flow of feed stream 44. The fuel cell stacks 38, 40 and 42when being built can each be compressed so that a pressure dropexperienced across each of the fuel cell stacks 38, 40 and 42 aresubstantially the same or in a common range of pressure drops.Alternatively, one or more fuel cell stacks 15 can be compressed whenbuilt or later have its compression adjusted to have a pressure dropthat substantially matches a pressure drop or range of pressure drop ofan existing fuel cell stack(s) and then used in parallel with theexisting fuel cell stack(s). By balancing the pressure drops across fuelcell stacks 38, 40 and 42, portions 48, 50 and 52 of feed stream 44 aresubstantially the same (all other influencing factors being equal (e.g.,piping restrictions)). Preferably, the pressure drops of each of thefuel cell stacks 38, 40, 42 are adjusted so that they occur atsubstantially the same power output or power output range.

Referring again to FIG. 4, the assembly and compression of fuel cellstack 15 is shown. A plurality of fuel cells 10 are arranged adjacentone another into a fuel cell assembly 54. Fuel cell assembly 54 ispositioned between a pair of terminal plates 56 that are used to conductelectrical current to/from fuel cell assembly 54. A pair of end plates16 are disposed adjacent terminal plates 56 on either side of fuel cellassembly 54. Compressive force F is applied to one or both end plates 16to compress fuel cell assembly 54. Reactant feed streams are provided tofuel cell stack 15 and operation of the fuel cell stack 15 is commenced.A power output of fuel cell stack 15 along with the pressure drop of oneor both of the feed streams across fuel cell stack 15 are measuredand/or monitored. Additionally, a velocity of the feed streams flowingthrough fuel cell stack 15 can also be measured and/or monitored. Theoperation of fuel cell stack 15 is adjusted until fuel cell stack 15 isoperating at a desired state (e.g., power level).

Compressive force F is then adjusted in magnitude until fuel cell stack15 exhibits a desired characteristic. For example, compressive force Fcan be adjusted until the pressure drop across fuel cell stack 15 is ofa predetermined magnitude, range of magnitudes, or until a minimum flowvelocity of one or more of the feed streams through the fuel cell stack15 is exceeded. The exact operating state of fuel cell stack 15 at thetime of adjusting the compressive force F will vary depending upon thedesired operation of fuel cell stack 15. For example, as stated above,when peak power output is critical or most important, fuel cell stack 15may be operated at 85-100% of peak power level while adjusting thecompressive force F. In contrast, when efficiency of fuel cell stack 15is most important, fuel cell stack 15 is operated at 10-30% of peakpower level while adjusting compressive force F.

Once compressive force F (and the associated intrusion of media 32 intoflow channel 20) has been adjusted to a level that gives a desiredoperational characteristic of fuel cell stack 15, end plates 16 aresecured to a pair of side plates 60. Compressive force F is thenremoved. Attachment of end plates 16 to side plates 60 cause end plates16 to remain at a fixed distance apart and maintain the compression offuel cell assembly 54. End plates 16 can be secured to side plate 60 ina variety of ways, as is known in the art. For example, mechanicalfastener 62 can be used to secure end plates 16 to side plates 60. Amore detailed description of the stack compression mechanism illustratedin FIG. 4 is set forth in U.S. application Ser. No. 10/136,781 filed onApr. 30, 2002, which is commonly owned by the assignee of the presentinvention and which disclosure is expressly incorporated by referenceherein. Alternatively, other means for compressing the fuel cell stackwhich provides a generally equalized compression load are known in theart and may be employed with the present invention.

While flow channels 20 are shown as being generally rectangular, itshould be understood that other shapes and configurations that allowcompressible diffusion media 32 to intrude into flow channels 20 anddecrease flow area 34, can be utilized without departing from the scopeof the present invention. Furthermore, while specific pressure drops andpower levels have been used to describe and illustrate the presentinvention, it should be understood that other pressure drops and otheroperational conditions of fuel cell stack 15 and/or fuel cells 10 can beutilized without departing from the scope of the present invention.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

1. A method of making a fuel cell stack comprising the steps of: (a)positioning a plurality of fuel cells adjacent one another, at least onefuel cell of said plurality of fuel cells having an electrode plate witha flow field formed therein, a membrane electrode assembly (MEA) and acompressible fluid-permeable diffusion media disposed between said MEAand said electrode plate; (b) compressing said adjacent fuel cellstogether so that in said at least one fuel cell a portion of saiddiffusion media intrudes into said flow field of said adjacent electrodeplate; and (c) adjusting said compression so that a feed stream flowingthrough the fuel cell stack experiences a pressure drop of apredetermined magnitude while maintaining at least some intrusion ofsaid portion of said diffusion media into said flow field.
 2. The methodof claim 1, wherein said predetermined pressure drop is in the range ofabout 0.1 to about 6 psi.
 3. The method of claim 1, wherein step (c)includes adjusting said compression while the fuel cell stack operatesat a predetermined power output.
 4. The method of claim 1, whereinadjusting said compression includes changing said intrusion of saiddiffusion media into said flow field.
 5. A method of making a fuel cellstack comprising the steps of: (a) positioning a plurality of fuel cellsadjacent one another, at least one fuel cell of said plurality of fuelcells having an electrode plate with a flow field formed therein, amembrane electrode assembly (MEA) and a compressible fluid-permeablediffusion media disposed between said MEA and said electrode plate; (b)compressing said adjacent fuel cells together so that in said at leastone fuel cell a portion of said diffusion media intrudes into said flowfield of said adjacent electrode plate; and (c) adjusting saidcompression so that a velocity of a feed stream flowing through the fuelcell stack is maintained above a predetermined level while maintainingat least some intrusion of said portion of said diffusion media intosaid flow field.
 6. The method of claim 5, wherein step (c) includesadjusting said compression while the fuel cell stack operates at apredetermined power output.
 7. The method of claim 5, wherein adjustingsaid compression includes changing said intrusion of said diffusionmedia into said flow field.
 8. A method of making a fuel cell stackcomprising the steps of: (a) positioning a plurality of fuel cellsadjacent one another, at least one fuel cell of said plurality of fuelcells having an electrode plate with a flow field formed therein, amembrane electrode assembly (MEA) and a compressible fluid-permeablediffusion media disposed between said MEA and said electrode plate; (b)compressing said adjacent fuel cells together so that in said at leastone fuel cell a portion of said diffusion media intrudes into said flowfield of said adjacent electrode plate; and (c) adjusting saidcompression so that a feed stream flowing through the fuel cell stackexperiences a pressure drop of a magnitude generally equal to a knownpressure drop of a different fuel cell stack.
 9. The method of claim 8,wherein adjusting said compression includes changing said intrusion ofsaid diffusion media into said flow field.
 10. The method of claim 8,wherein step (c) includes adjusting said compression while the fuel cellstack operates at a predetermined power output.
 11. A method of making afuel cell stack comprising the steps of: (a) positioning a plurality offuel cells adjacent one another, at least one fuel cell of saidplurality of fuel cells having an electrode plate with a flow fieldformed therein, a membrane electrode assembly (MEA) and a compressiblefluid-permeable diffusion media disposed between said MEA and saidelectrode plate; (b) compressing said adjacent fuel cells together sothat in said at least one fuel cell a portion of said diffusion mediaintrudes into said flow field of said adjacent electrode plate; and (c)adjusting said compression so that, at a predetermined power output ofthe fuel cell stack, a feed stream flowing through said fuel cell stackis adjusted toward a value corresponding to a known pressure drop of adifferent fuel cell stack at a substantially similar power output. 12.The method of claim 11, wherein adjusting said compression includeschanging said intrusion of said diffusion media into said flow field.13. The method of claim 11, wherein step (c) includes adjusting saidcompression while the fuel cell stack is operating at said predeterminedpower output.
 14. A method of making a fuel cell stack comprising thesteps of: (a) positioning a plurality of fuel cells adjacent oneanother, at least one fuel cell of said plurality of fuel cells havingan electrode plate with a flow field formed therein, a membraneelectrode assembly (MEA) and a compressible fluid-permeable diffusionmedia disposed between said MEA and said electrode plate; (b)compressing said adjacent fuel cells together so that in said at leastone fuel cell a portion of said diffusion media intrudes into said flowfield of said adjacent electrode plate; (c) supplying a fluid flowthrough said fuel cell stack including said flow field; and (d) changingan intrusion of said diffusion media into said flow field of saidadjacent electrode plate and achieving a predetermined flowcharacteristic while maintaining at least some intrusion of said portionof said diffusion media into said flow field.
 15. The method of claim14, wherein (d) includes adjusting said compression of said adjacentfuel cells to achieve said predetermined flow characteristic.
 16. Themethod of claim 14, wherein (d) includes achieving a flow characteristicwithin a predetermined range.
 17. The method of claim 14, wherein (d)includes achieving a predetermined pressure drop of the fluid flowthrough the fuel cell stack.
 18. The method of claim 14, wherein (d)includes achieving a flow velocity of said fluid flow through the fuelcell stack within a predetermined range of flow velocities.
 19. Themethod of claim 14, wherein step (d) includes changing said intrusionwhile the fuel cell stack is operating at a predetermined power output.20. A method of making a fuel cell stack comprising the steps of: (a)positioning a plurality of fuel cells adjacent one another, at least onefuel cell of said plurality of fuel cells having an electrode plate witha flow field formed therein, a membrane electrode assembly (MEA) and acompressible fluid-permeable diffusion media disposed between said MEAand said electrode plate; and (b) compressing said adjacent fuel cellstogether so that in said at least one fuel cell a portion of saiddiffusion media intrudes into said flow field of said adjacent electrodeplate and an uncompressed thickness of said media is reduced by at least10%.
 21. A method of making a fuel cell stack comprising the steps of:(a) positioning a plurality of fuel cells adjacent one another, at leastone fuel cell of said plurality of fuel cells having an electrode platewith a flow field formed therein, a membrane electrode assembly (MEA)and a compressible fluid-permeable diffusion media disposed between saidMEA and said electrode plate; (b) compressing said adjacent fuel cellstogether so that in said at least one fuel cell a portion of saiddiffusion media intrudes into said flow field of said adjacent electrodeplate; and (c) changing an intrusion of said diffusion media into saidflow field of said adjacent electrode plate and achieving apredetermined flow characteristic.
 22. The method of claim 21, whereinstep (c) includes changing said intrusion while the fuel cell stackoperates at a predetermined power output.
 23. A method of making a fuelcell stack comprising the steps of: positioning a plurality of fuelcells adjacent one another, at least one fuel cell of said plurality offuel cells having an electrode plate with a flow field formed therein, amembrane electrode assembly (MEA) and a compressible fluid-permeablediffusion media disposed between said MEA and said electrode plate;compressing said adjacent fuel cells together so that in said at leastone fuel cell a portion of said diffusion media intrudes into said flowfield of said adjacent electrode plate; supplying a fluid stream to saidplurality of fuel cells; monitoring a pressure drop of said fluid streamacross said plurality of fuel cells; and adjusting a compression of saidplurality of fuel cells so that said pressure drop is within apredetermined range.
 24. The method of claim 23, wherein adjusting saidcompression includes adjusting said compression while the fuel cellstack operates at a predetermined power output.